5s Lean Presentation

5 Steps to a
better workplace
World-Class-Manufacturing.com

World-Class-Manufacturing.com 2
The purpose of 5S is to
promote a safe and efficient
work environment
 5S is a method that uses
five Japanese words which
start with the letter S
What is 5S?
− Is it just another ”cleaning
campaign”?
− No – this is the end of one-
shot cleaning campaigns!

 How do we know if we have working 5S System?
− If we do not have to clean a bit extra before an important visit

 Improved safety
− No items on the floor
− Safety device in their right
places
− Less dust
− Better overview
− Less stress
Reasons to implement 5S

 Improved safety
 Fewer breakdowns
− Less wear from dust or grit in
moving parts
− Fewer errors from electronic
systems due to bad
environment

 Improved safety
 Better work environment
− A clean and well functioning
work place
− Fix the unsafe and cluttered
work stations

 Improved safety
 Less environmental impact
− Leakages such as oil will
easily be spotted
− Using less floor space may
reduce energy consumption

 Improved safety
 Fewer human errors
− No outdated work instructions
− Small but annoying faults are
fixed
− Fewer visual distractions
when working
− It should be easier to do it
right than wrong!

 Improved safety
 May find problems earlier
− When you clean a machine
you inspect at the same time

 Improved safety
 May find problems earlier
 No searching
− Effective tools at the right
place

•11
 Higher moral, motivation
 Practical training in Lean for
leaders and co-workers
 Better impression
 Easier to recruit good people
Indirect gains with 5S
Everyone should be able to work at a
workplace that they can proudly
present to others!

Think break
 What would be the benefits for us if we
implemented 5S?
 What problems do we have today?
 What could be root causes of today’s
problem?

The five steps in 5S
Seiri - Sorting
Seiton - Organizing
Seiso - Cleaning
Step 5 – Discipline
Seiketsu – Routines
Step 1
Step 2
Step 3
Step 4
Step 5

Step 1 – Sorting
 Sorting has two main
purposes
1. Remove unnecessary
objects
2. Reduce waste
 Sorting is a team activity
that will be carried out
by the production and
maintenance personnel
together
Step 1 – Sorting

 Go through the whole plant
− Machine and control positions
− Work areas
− Storage and common areas
 Look for
− Materials
− Behind or under machines
− Rejects
− ”Forgotten” material
Step 1 – Sorting
Remove unnecessary
objects

Go through the whole plant
−Machine / control positions
−Work area
−Storage and common areas
Look for
−Materials
−Tools
Not in use
Worn out or broken
”Custom-made” tools – made out
of tape or steel wire
Step 1 – Sorting
Remove unnecessary
objects

−Work area
Look for
−Materials
−Tools
−Spare parts
Broken
Surplus inventory
Spare parts for machines no
longer in use
Step 1 – Sorting
Remove unnecessary
objects

−Work area
Look for
−Materials
−Tools
−Spare parts
−Out-of-date Documentation
Instructions
Binders
Manuals
Common folders in the computer
system
Duplicates: digital and/or paper?
Step 1 – Sorting
Remove unnecessary
objects

−Work area
Look for
−Materials
−Tools
−Spare parts
−Out-of-date documentation
−Computerized systems
Step 1 – Sorting
Remove unnecessary
objects

−Work area
Look for
−Materials
−Tools
−Spare parts
−Out-of-date Documentation
−Bulletin board
−Other stuff
Outdated process equipment
Et. cetera
Step 1 – Sorting
Remove unnecessary
objects

 Look at each object
 Ask yourself: Do we need it at
all?
− If not – Discard it, or sell it
 Ask yourself: Will we need it
soon?
− If not – Put it into proper
storage (e.g. ”spare parts”)
Step 1 – Sorting
Remove unnecessary
objects

Step 1 Seiri - Sort
Each item to be discarded or
corrected is marked with a red
tag
The red tag gives everyone the
opportunity to speak up on the
proposed action.
A quarantine area can be created
for the object you are unsure of.
A red tag should never be up for
more than 30 days.
Date: Tagged by:
Item description:
Reason tagged:
Tag No:
Remove unnecessary
objects

Waste elimination
23
Step 1 – Sorting
 The second purpose of
sorting is to reduce waste
and generate ideas for
improvements
 We will try to identify
everything that is hindering
us from working safely and
efficiently

 Identify:
 Work instructions
− Do we have them?
− Are they up-to-date?
− Are they in use? If not – why not?
Step 1 – Sorting
Waste elimination

 Identify :
Work instructions
Safety
−What measures should we take to
eliminate the risk of fires and accidents?
Remove clutter
Improve unsafe electrical installations
Replace broken safety devices
Repair broken steps
Step 1 – Sorting
Waste elimination

 Identify :
Safety
Environment
−What measures do we need to
minimize or prevent damage to the
environment?
Step 1 – Sorting
Waste elimination

 Identify :
Safety
Environment
Tools and equipment
−Anything missing?
−Anything not working properly?
−Anything in need of improvement?
Step 1 – Sorting
Waste elimination

 Identify :
Safety
Environment
Inconvenient work positions
−Seating and work surfaces at
the right heights?
−...and adjustable for different
shift workers?
−Awkward angles for moving
materials?
Step 1 – Sorting
Waste elimination

 Identify :
Safety
Environment
Deferred maintenance
−temporary repairs (like tape and steel wire)
−obvious technical errors (like strange noises
or smells, leakage, dangling parts)
Step 1 – Sorting
Waste elimination

 Identify :
Safety
Environment
Deferred maintenance
Improvement Proposals
−review prior suggestions that were never implemented
measures aimed at improving quality, operating purposes,
procedures, controls, etc.
Step 1 – Sorting
Waste elimination

Step 1 – Sorting
All identified waste items are
marked with an red tag
Date: Tagged by:
Item description:
Reason tagged:
Tag No:
Waste elimination

Step 1 – Sorting
Machine tagged with errors and
improvement suggestions

Date: Tagged by:
Item description:
Reason tagged:
Tag No:
Step 1 – Sorting
Every tag refers to a 5S Sort list

Action plans after
5S sorting

Step 2 – Organizing
Steg 1
Steg 2
Step 1 – Sorting
Step 2 – Organizing The purpose is that
everything that we
regularly use should have
a convenient placement
− Tools should be kept at
the point of use
− No bending to pick up or
move materials
− Alter flow paths to
improve efficiency

A good
example

This presentation is based on the
book ”Succeeding with 5S” by
Oskar Olofsson
Download the full presentation at
http://world-class-
manufacturing.com
37

5s Lean Presentation

5s Lean Presentation

Recommended

More Related Content

What's hot

What's hot(20)

Similar to 5s Lean Presentation

Similar to 5s Lean Presentation(20)

Recently uploaded

Recently uploaded(20)

5s Lean Presentation